A pipe wear monitoring system and method of use thereof

ABSTRACT

The present invention relates to a system and method for monitoring wear in pipes, particularly irregular wear in pipelines transporting abrasive fluids. The system includes a plurality of wear sensors spaced along a length of a pipe. Each wear sensor is configured to detect wear in a wall of the pipe. The system further includes at least one remotely accessible server operatively connected to the sensors for receiving and monitoring data output from said sensors. The server is configured to alert an operator when said data received from any one of the plurality of sensors is indicative of irregular wear in the wall of the pipe.

TECHNICAL FIELD

The present invention relates to a system and method for monitoring wearin pipes, particularly irregular wear in pipes and pipelinestransporting abrasive fluids.

BACKGROUND

Pipeline transport is commonly used to transport materials through asystem of pipes—a pipeline—typically to a market area for consumption oruse. Generally, such pipelines may span several kilometres, in somecases hundreds of kilometres, and be used to transport crude and refinedpetroleum, fuels (e.g., oil, natural gas and biofuels) and other fluids,including sewage, slurry, tailings, or other heavy media materials.

A problem in general with such pipes or pipelines is that the pipes areprone to irregular wear, and in severe cases failure, when transportingabrasive materials, such as, e.g., slurry, tailings and other heavymedia materials.

Current best practice is to continually inspect pipes and pipelines andimplement corrective maintenance when and where failures are detected.While this practice may assist in early identification of pipe failures,it is not pre-emptive nor is it a time- or cost-effective approach,particularly when the pipes and pipelines may be located in remote andisolated areas.

SUMMARY OF INVENTION

Embodiments of the present invention provide a system, a sensor and amethod of use for monitoring wear along a length of a pipe, which may atleast partially address one or more of the problems or deficienciesmentioned above or which may provide the public with a useful orcommercial choice.

According to a first aspect of the present invention, there is provideda pipe wear monitoring system including:

a plurality of wear sensors spaced along a length of a pipe, each wearsensor configured to detect wear in a wall of the pipe; and

at least one remotely accessible server operatively connected to thesensors for receiving and monitoring data output from said sensors, saidserver configured to generate an alert when said data received from anyone of the plurality of sensors is indicative of irregular wear in thewall of the pipe.

According to a second aspect of the present invention, there is provideda pipe wear monitoring system including:

at least one base station;

a plurality of wear sensors spaced along a length of a pipe andoperatively connected to the at least one base station, each wear sensorconfigured to detect wear in a wall of the pipe; and

at least one remotely accessible server operatively connected to thebase station for receiving and monitoring data output from said sensorsvia said at least one base station, said server configured to generatean alert when said data received from any one of the plurality of wearsensors is indicative of irregular wear in the wall of the pipe.

According to a third aspect of the present invention, there is provideda pipe wear monitoring system including:

at least one base station;

a plurality of sensor nodes operatively connected to the at least onebase station, each sensor node operatively associated with at least onewear sensor spaced along a length of a pipe and configured to detectwear in a wall of the pipe; and

at least one remotely accessible server operatively connected to thebase station for receiving and monitoring data output from said sensorsvia said sensor nodes, said server configured to generate an alert whensaid data received from any one of the plurality of wear sensors isindicative of irregular wear in the wall of the pipe.

According to a fourth aspect of the present invention, there is provideda wear sensor for use in detecting irregular wear in a wall of a pipe,said sensor including:

a sacrificial probe configured to be at least partially inserted into anopening defined in an outer surface of a wall of a pipe and be at leastpartially destroyed in response to irregular wear on an inner surface ofthe pipe, the destruction of the probe being indicative of irregularwear being detected.

According to a fifth aspect of the present invention, there is provideda pipe wear monitoring system including:

a plurality of wear sensors according to the fourth aspect spaced alonga length of a pipe; and

at least one remotely accessible server operatively connected to thesensors for receiving and monitoring data output from said sensors, saidserver configured to generate an alert when said data received from anyone of the plurality of sensors is indicative of irregular wear in awall of the pipe.

Advantageously, the systems and methods of the present invention enablewear to be remotely monitored in a wall of a pipe. The systems andmethods obviate the need for continuous inspections for pipe wallfailures and associated costs by continuously or periodically monitoringthe thickness of a pipe wall. When a pipe wall thins due to irregularwall, an alert is generated alerting an operator to replace a failingsegment of pipe before it fails. Further, by providing advanced alertsof the failure of a pipe wall as opposed to reactive alerts, an operatoris able to coordinate and plan maintenance and repair operations in amore time- and cost-effective manner than the current practice ofcontinuous inspections.

As indicated above, the system and components thereof are for use withpipes, pipelines, and components and fittings thereof used to conveyabrasive materials and, thus, prone to irregular wear and failure.Examples of such components and fittings include launders, shuts andbins.

A person skilled in the art will appreciate that the system may also beused with pipes, pipelines, and components and fittings thereof thatconvey any flowable material or materials that may at least partiallydegrade or corrode an inner wall of a pipe, component or fitting, suchas, e.g., pipes that convey heavily acidic or alkalinic materials.Further, the system may be used with pipes, pipelines, and componentsand fittings thereof that may be subject to corrosion, such as, e.g.,iron pipes.

Further, a person skilled in the art will appreciate that the system maybe used with structure that has wear parts or units. For example, thesystem may be used with wear tiles or plates used in chute, a crusher, afeeder, a conveyor, a stacker or a grinding mill.

As used herein, the term “pipe” may encompass any tubular section usedto convey flowable medium, such as, e.g., liquids, gases, slurries,powders and masses of small solids.

Typically, the pipe may include a pair of opposed open ends and at leastone sidewall extending longitudinally between the ends. The at least onesidewall is usually curved such that the pipe has a circular profileshape, although non-circular shapes are also encompassed.

The pipe may be formed from any suitable material or materials capableof conveying the flowable medium. Generally, the pipe may be formed fromceramic, concrete fibreglass, plastic and/or metal material ormaterials, typically steel, copper, aluminium, concrete or plasticmaterial or materials, preferably steel or high-density polyethylene(HDPE).

In some embodiments, the pipe may be a wear resistant pipe.

For example, in some such embodiments, the pipe may have a thickenedsidewall to at least partially delay wear failure. The sidewall of thepipe may have thickness of between about 1.5 mm and about 100 mm, forexample.

In other such embodiments, the pipe may include a wear liner extendingalong an inner surface of the sidewall. The wear liner may be formedfrom any suitable wear resistant material, such as, e.g., ceramic.

As used herein, the term “pipeline” may encompass two or more segmentsor lengths of pipe joined end-to-end for conveying a flowable medium.

As used herein, the term “irregular wear” may include any non-uniformwear on an inner surface of a wall of a pipe.

Generally, the irregular wear may include a portion of the inner surfaceof the wall of the pipe that exhibits more advanced wear than otherportions of the pipe. FIG. 1 shows an example of irregular pipe wear.Specifically, FIG. 1 shows a portion (14) of a pipe (10) exhibiting moreadvanced wear and thinning of the sidewall (12) than other portions (16)of the pipe (10).

Typically, the irregular wear may occur on an inner surface of a bottomor lower portion of the wall of the pipe generally corresponding to thesurface most in contact with the materials being conveyed within thepipe, usually a slurry.

The wear sensors may be of any suitable size, shape and form for beingspaced along a length of the pipe. The wear sensors may be fitted orinstalled on the pipe at the time of manufacture or may be retro-fittedto an existing pipe, typically the latter.

The wear sensors may be spaced at regular intervals along a length ofthe pipe, typically to a lower side or portion of the pipe. For example,the wear sensors maybe spaced at intervals of about 0.5 m, about 1 m,about 1.5 m, about 2 m, about 2.5 m, about 3 m, about 3.5 m, about 4 m,about 4.5 m, about 5 m, about 5.5 m, about 6 m, about 6.5 m, about 7 m,about 7.5 m, about 8 m, about 8.5 m, about 9 m, about 9.5 m, about 10 m,about 10.5 m, about 11 m, about 11.5 m, about 12 m, about 12.5 m, about13 m, about 13.5 m, about 14 m, about 14.5 m, about 15 m, about 15.5 m,about 16 m, about 16.5 m, about 17 m, about 17.5 m, about 18 m, about18.5 m, about 19 m, about 19.5 m or even about 20 m or more along alength of the pipe.

Each wear sensor may be fitted or installed to the sidewall of the pipein any suitable way such that the sensor can detect wear in the wall ofthe pipe, preferably on an inner surface of the wall.

For example, in some embodiments, the wear sensors may be attached orfastened to an outer surface of the sidewall of the pipe with one ormore fasteners, such as, e.g., one or more chemical fasteners and/or oneor more mechanical fasteners.

In some such embodiments, each wear sensor may be fastened to the outersurface of the sidewall by one or more chemical fasteners. The one ormore chemical fasteners may include a wet adhesive, a dry adhesiveand/or double-sided adhesive tape extending between the sensor and theouter surface.

In other such embodiments, each wear sensor may be fastened to the outersurface of the sidewall by one or more mechanicals fasteners. The one ormore mechanical fasteners may include one or more threaded fasteners orrivets.

In other embodiments, each sensor and the pipe may be attached orconnected together by a connecting mechanism or part of a connectingmechanism. The connecting mechanism may include a first part associatedwith the sensor and a second part connectable to the first partassociated with the sidewall of the pipe.

The parts of the connecting mechanism may include mateable male andfemale portions that couple together, included threaded connections,interference (snap fit) connections, and/or bayonet-type connections,for example.

For example, in some such embodiments, a first part of the connectingmechanism associated with the sensor may be include a male formationconfigured to be at least partially inserted into or coupled with afemale formation of a second part of the connecting mechanism associatedwith the sidewall.

Conversely in other such embodiments, the first part of the connectingmechanism associated with the sensor may include a female formationconfigured to at least partially receive or couple with a male formationof the second part of the connecting mechanism associated with thesidewall.

In yet other embodiments, the wear sensors may be at least partiallyreceived in a sensor inlet port defined in the outer surface of thesidewall of the pipe. The sensor inlet port may include an openingdefined in the outer surface of the sidewall of the pipe and extendingpartially towards an inner surface of the sidewall but not through theinner surface. Preferably, the sensor inlet port may include a threadedinner surface for threadingly engaging with an outer surface of the wearsensor.

As indicated, the wear sensors may be of any suitable type capable ofdetecting wear in the sidewall of a pipe.

For example, in some embodiments, the wear sensor may include atemperature sensor capable of detecting a change in temperature relatingto the flowable medium temperature and corresponding to a thinning ofthe wall of the pipe.

In such embodiments, the sensor may be at least partially received in asensor inlet port in the wall of the pipe and detection of the flowablemedium temperature may be indicative of wear in the wall of the pipe.

The temperature sensor may be a thermistor, a thermocouple, a resistancethermometer or a silicon bandgap temperature sensor, for example.

In other embodiments, the wear sensor may be an electric sensorconfigured to be associated with a sidewall of the pipe and generate asignal when the sidewall thins to a predetermined thickness, preferablyan electronic signal.

In yet other embodiments, the wear sensor may be a sacrificial wearsensor. For example, the wear sensor may include a sacrificial probeconfigured to be at least partially destroyed in response to wear in thesidewall of the pipe, partial destruction of the probe being indicativeof said wear being detected.

In such embodiments, the probe may preferably be an electronicsacrificial probe configured to generate a signal indicative of wearbeing detected. The signal may be an electronic signal or the absence ofan electronic signal generated as a result of the partial destruction ofthe probe.

In preferred such embodiments, the sacrificial probe may include a boardhaving at least one electrical circuit defined thereon. The board andthe at least one circuit may be configured to be at least partiallydestroyed in response to wear in the sidewall of the pipe.

In other preferred such embodiments, the board of the sacrificial probemay have a plurality of electrical circuits defined thereon. Theindividual circuit and the board are configured to be sequentiallydestroyed in response to wear in the sidewall of the pipe. Thesequential destruction of the individual circuits enables wear in thesidewall of the pipe to be incrementally monitored. Advantageously, thisalso enables a wear rate to be determined.

For example, in use, the electrical circuit may be continuously orperiodically polled by the system. When the electrical circuit isintact, the circuit may generate a signal when polled indicative of theabsence of irregular wear on the sidewall. When the circuit is at leastpartially destroyed, the circuit will not generate a signal when polled,thereby indicative of irregular wear on the sidewall.

The wear sensor may preferably include a body for at least partiallyhousing the sacrificial probe and for connecting, fastening or attachingthe wear sensor to the sidewall of the pipe. Typically, the body may beat least partially formed from the same material or materials as thepipe to which it is connected, fastened or attached.

Generally, the body may be of a corresponding size and shape to besecurely received in the sensor inlet port. Typically, the body may havea substantially circular profile shape. Preferably, the body may have asubstantially cylindrical shape.

The body may include a shank having a pair of opposed ends, a head atone of the opposed ends and a tip at the other of the opposed ends ofthe shank.

The shank may be sized and shaped such that it may at least partiallyextend within the sensor inlet port. The shank may be at least partiallythreaded, preferably along a portion of a length of the shankimmediately adjacent the head. Preferably, the shank may include anexternal thread.

The shank may have any suitable thread profile to threadingly engagewith an internal thread provided in the sensor inlet port. For example,the external thread may have a square, triangle, trapezoidal or otherthread shape. Preferably, the threaded portion of the shank may have asquare thread profile.

The head may preferably be an enlarged head sized and shaped such thatit may not be received within the sensor inlet port but may abut againstan outer surface of the wall of the pipe.

In some embodiments, the head may include a tool engaging formation,such as, e.g., a socket, formed in the head for receiving a tool forapplying torque to the body and turning or rotating body relative to thesensor inlet port.

In other embodiments, the head may include a non-circular head profileshape for engaging with a tool for applying torque to the body andturning or rotating body relative to the sensor inlet port. For example,the head may include a hexagonal profile shape for engaging with awrench or the like.

The tip of the body may be rounded, blunt or square-tipped. Likewise, adistal end of the shank at or near the tip may or may not be threaded.

The body may further include an internal passage extending through thebody, preferably from the tip at least partially towards the head. Theinternal passage may be of any suitable size for receiving and holdingin place the sacrificial probe. Typically, the passage may extendlongitudinally through the body, preferably along a central axis of thebody. The passage may have a circular profile shape for accommodatingthe sacrificial probe.

In some embodiments, the internal passage may include at least twosub-passages, including a first sub-passage extending from the tip ofthe body at least partially towards the head of the body for receivingand accommodating the sacrificial probe and a second sub-passageextending from the first sub-passage and entirely through the head ofthe body for the passage of any cables or wires connected to thesacrificial probe. The second sub-passage may have a narrower diameteror width than the first sub-passage to prevent passage of thesacrificial probe therethrough.

In use, the sacrificial probe may be inserted into the body via the tipprior to the sensor being at least partially inserted into andthreadingly engaging with the sensor inlet port.

In some embodiments, the sacrificial probe may include at least oneretaining portion for engaging with the tip of the body and preventingover-insertion of the probe into the body. Typically, the probe mayinclude a pair of opposed retaining portions configured to engage withdiametrically opposite sides of the tip of the body. In preferred suchembodiments, the retaining portions may include a pair of outwardlyturned end edges of the sacrificial probe configured to at leastpartially hook or clip over the tip of the body.

In some embodiments, each sensor may include a communications module forconnecting the sensor to the at least one remotely accessible server orthe base station. The sensor may connect to the server or the basestation in any suitable way.

For example, the communications module may be in the form of a modemenabling the sensor to connect to the server or the base station via awired or wireless network, preferably the latter.

In some embodiments, the communications module may include a port oraccess point (e.g., a USB port, a mini-USB port or an Ethernet port)such that the sensor may be connected to an external processing device,such as, e.g., the sensor node, using a suitable cable.

In other embodiments, the communications module may be a wirelesscommunications module, such as, e.g., a wireless network interfacecontroller, such that the sensor may wirelessly connect to the basestation or the server through a wireless network (e.g., Wi-Fi (WLAN)communication, Satellite communication, RF communication, infraredcommunication, or Bluetooth™).

In yet other embodiments, the communications module may include at leastone modem configured to be in wireless communication with the server orthe base station for the transmission of data. In some such embodiments,the modem may be a cellular modem. In other embodiments, the modem maybe a radio modem.

The communications module may be connected to the sacrificial probe byan electrical circuit, typically extending along at least one cableextending through the head of the body. The electrical circuit mayinclude a data bus, a twisted pair network and/or a fibre optic network,for example. Excitation/operating voltage may be supplied over thecircuit (such as POE) or separately.

In some embodiments, each sensor may further include a power supply forpowering the sacrificial probe, the communications module and otherelectrical components of the sensor. The power supply may preferablyinclude an on-board power source, such as, e.g., one or more batteries,preferably rechargeable batteries.

Each sensor may be addressable and may report an operational status tothe sensor node, the base station and/or the remotely accessible serverwhen polled or interrogated.

As indicated above, in some embodiments the system may include at leastone base station operatively associated with the plurality of wearsensors and the remotely accessible server for at least relaying databetween from the sensors and the server. The at least one base stationmay be of any suitable size, shape and construction and formed from anysuitable material or materials.

Preferably, the at least one base station may function as a bridgebetween the plurality of sensors and the remotely accessible server.

Generally, the at least one base station may be located at or near thepipe so that the base station may be operatively associated with theplurality of sensors or a subset of the plurality. For example, in someembodiments, the at least one base station may be located at or near anend of the pipe or pipeline. In other embodiments, the at least one basestation may be located at a position partially along a length of thepipe.

In some embodiments, the system may include more than one base stationeach operatively associated with a subset of the plurality of sensors.For example, the system may include at least two base stations, at leastthree base stations, at least four base stations or even at least fivebase stations. In such embodiments, the base stations may be located atspaced intervals along the pipe or pipeline.

The base station may include a body sized and shaped for housingcomponents and/or parts of the system, including at least one powersource and a communications module. Preferably, the body may be formedfrom a durable material or materials configured to withstand externalenvironmental exposure, such as, e.g., plastic, concrete and/or metalmaterial or materials.

As indicated, the base station may include a communications module forconnecting to the plurality of sensors and the at least one remotelyaccessibly server. The base station may connect in any suitable way.

The communications module may preferably be a modem enabling the atleast one base station to connect to the remotely accessible server viaa wireless network (e.g., Wi-Fi (WLAN) communication, Satellitecommunication, RF communication, infrared communication, or Bluetooth™).For example, and as indicated above, in some embodiments, the modem maybe a cellular modem. In other embodiments, the modem may be a radiomodem.

As also indicated, the base station may include at least one powersource for powering at least the communications module. In someembodiments, the power source may include an on-board power source, suchas, e.g., one or more batteries. In other embodiments, the power sourcemay include one or more photovoltaic cells, an inverter and one or morebatteries for storing electricity generated and from which the basestation may draw power. In yet other embodiments, the power source mayinclude a mains supply.

In some embodiments, the at least one base station may include amicrocomputer, including one or more processors and a memory, forreceiving, monitoring and transmitting data between the remotelyaccessible server and the plurality of sensors. The one or moreprocessors may be low power processors.

The processors may include multiple inputs and outputs coupled to thecommunications module for the receiving and transmitting of data. Forexample, in some such embodiments, the at least one base station mayperiodically or continuously address each sensor and report theoperational status of the sensor to the server. The operational statusmay include whether the sensor is operational, i.e., intact, anindication of any faults reported by the sensor, and/or an indication ofthe status of the power supply.

As indicated above, in some embodiments, the system may include aplurality of sensor nodes each operatively associated with at least onwear sensor for at least relaying data between the sensor and theserver, via the at least one base station. The sensor nodes may be ofany suitable size, shape and construction and formed from any suitablematerial or materials.

Like with the base station, each sensor node may include a body sizedand shaped for housing components and/or parts of the system, includingat least one power source and a communications module. Preferably, thebody may be formed from a durable material or materials configured towithstand external environmental exposure, such as, e.g., plastic,concrete and/or metal material or materials.

Each sensor node may be operatively associated with any number of wearsensors. For example, each sensor node may be operatively associatedwith one, two, three, four, five, six, seven, eight, nine, 10, 11, 12,13, 14, 15, 16, 17, 18, 19 or 20 or more sensors.

Each sensor node may typically be operatively associated by a wiredconnection with the at least one wear sensor, although a wirelessconnection is also envisaged. Accordingly, usually each sensor node maybe located at or near the pipe in the immediate vicinity of theplurality of wear sensors or a subset thereof to which it is connected.

For example, in some embodiments, each sensor node may be operativelyassociated with an outer portion of a head of a body associated witheach wear sensor, preferably such that the sensor node may be connectedto a portion of the head protruding from an outer surface of a wall of apipe.

In some embodiments, the communications module may include a port oraccess point (e.g., a USB port, a mini-USB port or an Ethernet port) forconnecting the sensor node to the sensors, using a suitable cable.

In some embodiments, the communications module may further include atleast one modem enabling wireless communication with the at least oneremotely accessible server via the at least one base station for thetransmission of data between the sensor node, the at least one basestation and the at least one remotely accessible server. The wirelesscommunication may be via a wireless network (e.g., Wi-Fi (WLAN)communication, Satellite communication, RF communication, infraredcommunication, or Bluetooth™). Again, the modem may include a cellularmodem or a radio modem.

The sensor node may preferably include at least one power source forpowering at least the communications module. Typically, the power sourcemay include an on-board power source, such as, e.g., one or morebatteries, preferably rechargeable. In some embodiments, the powersource may include one or more photovoltaic cells, an inverter and oneor more batteries for storing electricity generated and from which thesensor node may draw power.

Again and like with the base station, in some embodiments, each sensornode may further include a microcomputer, including one or moreprocessors and a memory, for receiving, monitoring and transmitting databetween the at least one remotely accessible server, the at least onebase station and the plurality of sensors. The one or more processorsmay be low power processors.

The processors may include multiple inputs and outputs coupled to thecommunications module for the receiving and transmitting of data. Forexample, in some such embodiments, each sensor node may periodically orcontinuously address each sensor operatively associated with the nodeand report the operational status of the sensor to the remotelyaccessible server via the at least one base station. The operationalstatus may include whether the sensor is operational, i.e., intact, anindication of any faults reported by the sensor, and/or an indication ofthe status of the power supply (e.g., battery charge status).

Preferably, each sensor node may be configured to periodically orcontinually address each sensor it is operatively associated with andreport the operational status of the sensor to the remotely accessibleserver via the at least one base station. In some embodiments, thesensor node may only report an irregular operational status. In otherembodiments, the sensor node may report all operational statuses,including regular and irregular statuses.

The remotely accessible server may be any appropriate server computer,distributed server computer, cloud-based server computer, sever computercluster or the like. The server may also typically include one or moreprocessors and one or more memory units containing executableinstructions/software to be executed by the one or more processors.Generally, the server may be in communication with at least onedatabase.

For example, in some embodiments, the server may be in communicationwith a pipe database containing a plurality of sensor records for eachpipe being monitored. The server may preferably be linked to or maymaintain the pipe database. Each sensor record may include a sensoridentifier. Each sensor record may further include a past record of thedata output for the respective sensor.

In some embodiments, the remotely accessible server may additionallycollect and record the data output from said sensors in the pipedatabase, preferably against a sensor record corresponding to arespective sensor.

In some embodiments, the remotely accessible server may furthercontinuously or periodically monitor the pipe database for changes inthe data output for any one of the plurality of sensors. The remotelyaccessibly server may generate an alert when a change in the data outputis indicative of a change in sensor operational status, such as, e.g., asensor fail or failing sensor (imminent failure). The alert may begenerated to a computing device of an operator or the like. The alertmay be an electronic notification as will be described later.

As indicated above, the server may generally be in communication withthe plurality of sensors either directly or via one or more of thesensor nodes and the at least one base station.

The remotely accessible server may be configured to transmitcommunications to and receive communications from the sensors, thesensor nodes and/or the at least one base station over a communicationsnetwork, which may include, among others, the Internet, LANs, WANs, GPRSnetwork, a mobile communications network, a radio network (UHF-band),etc., and may include wire and/or wireless communication links,preferably the latter.

In some embodiments, the communications may be received and transmittedvia a private network connection established between the sensors, thesensor nodes and/or the at least one base station and the remotelyaccessible server.

For example, in some embodiments, the private network connection may bea secure communication session across an encrypted communication channelsuch as Hypertext Transfer Protocol Secure (HTTPS), Transport LayerSecurity/Secure Sockets Layer (TLS/SSL) or some other secure channel.

In other embodiments, the private network connection may be a VPNconnection established using an encrypted layered tunnelling protocoland authentication methods, including identifiers, passwords and/orcertificates.

For example, in some such embodiments, the sensors, the sensor nodesand/or the at least one base station may each be assigned a uniqueidentifier that may be registered with the server. In use, the servermay establish a VPN connection with the sensors, the sensor nodes and/orthe at least one base station upon authenticating the identifierassigned to the sensors, the sensor nodes and/or the at least one basestation.

In such embodiments, the server may be in communication with at leastone identifier database containing the plurality of identifiers. Theserver may look-up an identifier in the database to authenticate thesensors, the sensor nodes and/or the at least one base station. Theserver may again be linked to or may maintain the database containingthe plurality of identifiers.

As indicated, the at least one remotely accessible server may at leastreceive and monitor data output from the plurality of sensors,preferably on a real-time basis. Preferably, the server may monitor thedata received for any changes indicative of: an abnormal sensoroperating condition; a sensor failure; and/or irregular wear in the wallof the pipe to which the sensor is associated. For example, an abnormalsensor operating condition may include, inter alia, a low power warningor a high operating temperature warning. A failure may include, interalia, an open circuit, a short circuit or a power source failure.

Responsive to the remotely accessible server identifying data indicativeof irregular wear, the server may generate an alert to a computingdevice of an operator or the like advising of the irregular wear.

An alert generated by the remotely accessible server may preferably bean electronic notification and may be effected by way of Short MessageServer (SMS) protocol, Unstructured Supplementary Service Data (USSD)protocol, over a secure Internet connection, or by way of datacommunication enabled by a software application installed on thecomputing device, for example.

The computing device may include a computer, a tablet, a smart phone, asmart watch or a PDA, for example. The computing device may be connectedto the at least one remotely accessible server by a wired connection ora wireless connection via a wireless network (e.g., Wi-Fi (WLAN)communication, RF communication, infrared communication, or Bluetooth™),preferably the latter.

In some embodiments, the system may include software configured to berun on the sensors, the sensor nodes, the at least one base station, theremotely accessible server and/or the computing device of the operatoror the like. The software may preferably be interactive. In some suchembodiments, the software may be in the form of an application (i.e., anapp) configured to be run on a smart phone, a tablet or other mobilecomputing device, for example.

In other embodiments, the remotely accessible server may include a webserver providing a graphical user interface through which the operatoror the like may interact with the system and the remotely accessibleserver. The web server may accept requests, such as HTTP requests andserver responses, such as HTTP responses, along with optional datacontent, such as web pages (e.g., HTML documents) and linked objects.Generally, the web server may enable the operator and the like toreceive and transmit communications with the remotely accessible serverand with the sensors, the sensor nodes and/or the at least one basestation via the remotely accessible server.

According to a sixth aspect of the present invention, there is provideda wear monitoring system including:

a plurality of wear sensors configured to be at least partially insertedin wear parts or units of a structure; and

at least one remotely accessible server operatively connected to thesensors for receiving and monitoring data output from said sensors, saidserver configured to generate an alert when said data received from anyone of the plurality of sensors is indicative of at least one ofirregular wear or failure of any one of the wear parts or units of thestructure.

The wear system may include one or more characteristics of the pipe wearmonitoring system as hereinbefore described.

For example, the system may further include at least one base stationand/or a plurality of sensor nodes as previously described.

The wear parts or units may generally be of any suitable size, shape andconstruction to be partially resistant to wear and to protect at leastone side or internal side of the structure. The structure may be achute, a crusher, a feeder, a conveyor, a stacker or a grinding mill.

Generally, each wear sensor may be at least partially inserted into astructure-facing surface of the wear part or unit.

According to a seventh aspect of the present invention, there isprovided a method of monitoring pipe wear including:

providing a plurality of wear sensors at spaced intervals along a lengthof a pipe, each sensor being configured to detect wear in a wall of thepipe; and

receiving and monitoring data corresponding to data output from saidsensors and generating an alert when data is received from any one ofthe plurality of wear sensors indicative of irregular wear in the wallof the pipe.

According to an eighth aspect of the present invention, there isprovided a method of monitoring pipe wear including:

providing a plurality of wear sensors according to the fourth aspect atspaced intervals along a length of a pipe; and

receiving and monitoring data corresponding to data output from saidsensors and generating an alert when data is received from any one ofthe plurality of wear sensors indicative of irregular wear in a wall ofthe pipe.

The method of the seventh or eighth aspects may include one or morecharacteristics of the system and/or sensor as hereinbefore described.

The receiving and monitoring of data may preferably occur via theremotely accessible server, which may be in wireless communication withthe plurality of sensors, the plurality of sensor nodes and/or the atleast one base station, preferably via a wireless network.

In some embodiments, each sensor node operatively associated with aplurality of sensors may periodically or continually address each sensorand report an operational status of the sensor to the remotelyaccessible server, optionally via the at least one base station. In somesuch embodiments, the sensor node may report when a sensor does notrespond when polled, failure to respond being indicative of partialdestruction of the sensor and thus irregular wear on a portion of thepipe adjacent the sensor.

The addressing of each sensor may include verifying that at least thesensor probe is intact. The verifying may include transmitting anelectrical current through the electrical circuit provided on the sensorprobe, wherein a closed circuit is indicative that the sensor probe isintact and wherein an interrupted or open circuit is indicative that thesensor probe has been partially destroyed and thus irregular wear hasoccurred on a portion of the pipe at least adjacent the sensor.

Conversely in other embodiments, the at least one base station and/orthe remotely accessible server may periodically or continually addresseach sensor. In some such embodiments, the at least one base station mayreport an operational status of the sensor to the remotely accessibleserver. The at least one base station and/or the remotely accessibleserver may monitor each sensor for a response when polled, wherein theabsence of a response may be indicative of partial destruction of thesensor and thus irregular wear on a portion of the pipe adjacent thesensor.

In such embodiments, the at least one base station and/or the remotelyaccessible server may instruct the sensor to verify that the sensorprobe is intact. The verifying may include transmitting an electricalcurrent through the electrical circuit provided on the sensor probe,wherein a closed circuit is indicative that the sensor probe is intactand wherein an interrupted or open circuit is indicative that the sensorprobe has been partially destroyed and thus irregular wear has occurredon a portion of the pipe at least adjacent the sensor.

Responsive to the remotely accessible server identifying data indicativeof irregular wear, the server may generate an alert advising of theirregular wear, typically the alert is transmitted to a computing ormobile device of an operator or the like.

The alert may be an electronic notification and may be effected by wayof Short Message Server (SMS) protocol, Unstructured SupplementaryService Data (USSD) protocol, over a secure Internet connection, or byway of data communication enabled by a software application installed onthe computing device, for example.

Upon receiving the alert, an operator or the like may schedule orcommence repair or replacement of a portion of the pipe or pipelinecorresponding to the irregular wear advantageously before pipe wallfailure occurs.

Any of the features described herein can be combined in any combinationwith any one or more of the other features described herein within thescope of the invention.

The reference to any prior art in this specification is not and shouldnot be taken as an acknowledgement or any form of suggestion that theprior art forms part of the common general knowledge.

BRIEF DESCRIPTION OF DRAWINGS

Preferred features, embodiments and variations of the invention may bediscerned from the following Detailed Description which providessufficient information for those skilled in the art to perform theinvention. The Detailed Description is not to be regarded as limitingthe scope of the preceding Summary of Invention in any way. The DetailedDescription will make reference to a number of drawings as follows:

FIG. 1 is a photograph showing a sectional view of a pipe with irregularwear;

FIG. 2 is an illustration of a pipe wear monitoring system according toan embodiment of the present invention;

FIG. 3 is an illustration of a pipe wear monitoring system according toanother embodiment of the present invention;

FIG. 4 is an illustration of a pipe wear monitoring system according toanother embodiment of the present invention;

FIGS. 5A and 5B respectively show a wear sensor assembly according to anembodiment of the present invention;

FIG. 6 is a schematic showing a probe of the wear sensor shown in FIGS.5A and 5B;

FIG. 7 is a schematic showing a probe of the wear sensor according toanother embodiment of the present invention;

FIG. 8 is a screenshot of software for use in interacting with thesystem as shown in FIGS. 2 to 4; and

FIG. 9 is a flowchart showing steps in a method of monitoring pipe wearaccording to an embodiment of the present invention.

DETAILED DESCRIPTION

FIGS. 2 to 8 show embodiments of a pipe wear monitoring system (100) andparts thereof for monitoring wear along a length of a pipe (10).

Referring to FIG. 2, in this first embodiment, the system (100) includesa plurality of wear sensors (110) spaced along a length of a pipe (10).Each wear sensor (110) is configured to detect wear in a wall (12) ofthe pipe (10).

The system (100) further includes a remotely accessible server (1000)operatively connected to the sensors (110) for receiving and monitoringdata output from said sensors (110) in a periodic basis or in real-time.The server (1000) is configured to generate an alert in the form of anelectronic notification to a computing device (700) of an operator orthe like when said data received from any one of the sensors (110) isindicative of irregular wear in the wall (12) of the pipe (10).

Generally, the pipe (10) is a wear resistant pipe have a thickenedsidewall (12) to at least partially delay wear failure.

The wear sensors (110) are spaced at regular 1 m intervals along alength of the pipe (10) and are mounted to a lower side or portion ofthe pipe (10).

Each wear sensor (110) is threadingly received in a sensor inlet port(18) defined in the outer surface of the sidewall (12) of the pipe (10).The sensor inlet port (18) includes an opening defined in the outersurface and extending partially towards an inner surface of the sidewall(12) but not through the inner surface of sidewall (12). The sensorinlet port (18) includes a threaded inner surface for threadinglyengaging with an outer surface of the wear sensor (110).

Referring to FIGS. 5A and 5B, the wear sensor (110) is an electronicsacrificial wear sensor. The wear sensor (110) includes a sacrificialprobe (112) configured to be at least partially destroyed in response towear in the sidewall (12; not shown) of a pipe (10; not shown). Thepartial destruction of the probe (112) being indicative of wear beingdetected.

Best shown in FIG. 6, the sacrificial probe (112) includes a board (114)having an electrical circuit (116) defined thereon. The board (114) andcircuit (116) are configured to be at least partially destroyed inresponse to wear in the sidewall (12; not shown) of a pipe (10; notshown). As shown, the circuit (116) is printed at or near a distal outerend of the board (114) to thereby be sensitive to wear.

In use, the electrical circuit (116) is periodically polled by thesystem (100). When the electrical circuit (116) is intact, the circuit(116) generates a signal when polled indicative of the absence ofirregular wear on the sidewall (112; not shown). When the circuit (116)is at least partially destroyed, the circuit (116) will not generate asignal when polled, thereby indicative of irregular wear on the sidewall(12; not shown).

In FIG. 7, another embodiment of the sacrificial probe (112) is shown.The probe (112) again includes a board (114) having a plurality ofelectrical circuits (116) defined thereon. In this embodiment, theindividual circuits (116) and the board (114) are configured to besequentially at least partially destroyed in response to wear in thesidewall (12; not shown) of a pipe (10; not shown). Like with thesacrificial probe (112) shown in FIG. 6, the circuits (116) are printedat or near a distal outer end of the board (114) to thereby be sensitiveto wear.

Advantageously, the sequential destruction of the individual circuits(116) enables wear in the sidewall (12; not shown) of the pipe (10; notshown) to be incrementally monitored and/or enables a wear rate to bedetermined.

Referring again to FIGS. 5A and 5B, the wear sensor (110) furtherincludes a body (120) for at least partially housing the sacrificialprobe (112) and for threadingly engaging with the sensor inlet port (18;not shown) defined in the outer surface of the sidewall (12; not shown)of the pipe (10; not shown).

The body (120) includes a shank (122) having a pair of opposed ends,including a head (124) at one of the opposed ends and a tip (126) at theother of the opposed ends of the shank (122).

The shank (122) is sized and shaped to at least partially extend withina sensor inlet port (18; not shown) and position the sacrificial probe(112) at or near the inner surface of the sidewall (12) of the pipe (10)for detecting wear. The shank (122) includes an external thread (123).

The head (124) is enlarged and sized and shaped such that it cannot bereceived within the sensor inlet port (18; not shown) but rather abutsagainst an outer surface of the wall (12) of the pipe (10).

As best shown in FIG. 5B, the head (124) includes a hexagonal profileshape for engaging with a tool, such as, e.g., a wrench, for applyingtorque to the body (120) and turning or rotating body (120) relative tothe sensor inlet port (18; not shown) for installing and removing thewear sensor (110).

The tip (126) of the body (120) is square-tipped.

Again best shown in FIG. 5B, the body (120) further includes a firstinternal passage (128) extending through the body (120) from the tip(126) at least partially towards the head (124). The first internalpassage (128) is suitably sized and shaped for receiving and holding inplace the sacrificial probe (112).

Referring to FIG. 5A, the body (120) includes a second internal passage(not visible) extending through the head (124) of the body (120) and influid communication with the first internal passage (128) for passage ofcables connected to the sacrificial probe (112). The second internalpassage (not visible) has a narrower diameter or width than the firstinternal passage (128; shown in FIG. 5B) to prevent passage of thesacrificial probe (112) therethrough.

When assembling, the sacrificial probe (112) inserted into the body(120) via the tip (126) prior to the sensor (110) being at leastpartially inserted into and threadingly engaging with the sensor inletport (18; not shown).

Best shown in FIG. 5B, the sacrificial probe (112) includes pair ofoutwardly turned ends (119) for engaging with the tip (126) of the body(120) and preventing over-insertion of the probe (112) into the body(120). The ends (119) of the sacrificial probe (112) at least partiallyhook or clip over the tip (126) of the body (120).

Referring back to FIG. 2, in this first embodiment, each wear sensor(110) includes a communications module in the form of a cellular orradio modem for connecting the sensors (110) to the remotely accessibleserver (1000) via a wireless network, which may include, among others,the Internet, LANs, WANs, GPRS network, a mobile communications network,a radio network (UHF-band).

The communications module is connected to the sacrificial probe (112;not shown) by an electrical circuit extending along at least one cableextending through the head (124; not shown) of the body (120).

Each sensor (110) furthers include a power supply for powering thesacrificial probe (112; not shown), the communications module and otherelectrical components of the sensor (110). The power supply includes oneor more rechargeable batteries.

Each sensor (110) is addressable and reports an operational status tothe remotely accessible server (1000), when polled.

The remotely accessible server (1000) includes one or more processorsand one or more memory units containing executable instructions/softwareto be executed by the one or more processors.

The server (1000) is in communication with a pipe database (1010)containing a plurality of sensor records for each pipe being monitored.The server (1000) is linked to or can maintain the pipe database (1010).Each sensor record may include a sensor identifier. Each sensor recordfurther includes a past record of the data output for the respectivesensor (110).

In addition to receiving and monitoring, the remotely accessible server(1000) additionally collects and records the data output from thesensors (110) in the pipe database (1010).

The remotely accessible server (1000) further continuously orperiodically monitors the pipe database (1010) for changes in the dataoutput for any one of the plurality of sensors (110). The remotelyaccessibly server (1000) generates an alert when a change in the dataoutput is indicative of a change in sensor operational status, such as,e.g., a sensor fail or failing sensor (imminent failure). The alert isgenerated to a computing device (700) of an operator or the like. Thealert is an electronic notification, which will be described later.

The server (1000) is in communication with the plurality of sensors(110).

The server (1000) is configured to transmit communications to andreceive communications from the sensors (110) via a wireless network,which may include, among others, the Internet, LANs, WANs, GPRS network,a mobile communications network, a radio network (UHF-band).

Responsive to the server (1000) receiving, monitoring and identifyingdata indicative of irregular wear, the server (1000) generates an alertto a computing device (700) of an operator or the like advising of theirregular wear.

The alert generated is an electronic notification and may be effected byway of Short Message Server (SMS) protocol, Unstructured SupplementaryService Data (USSD) protocol, over a secure Internet connection, or byway of data communication enabled by software on the computing device,for example.

The computing device can include a computer, a tablet, a smart phone, asmart watch or a PDA, for example.

Referring briefly to FIG. 8, this figure shows a screen-shot (810) ofsoftware run on a computing device (800; not shown) for controllingoperation of the system (100; not shown).

As shown, the screen-shot (810) in this embodiment is reporting that theoperational status of all sensors (110; not shown) is “OK”. Thescreen-shot also shows a satellite view of the pipe (10; not shown).

FIG. 3 shows a second embodiment of the system (100) for monitoring wearalong a length of a pipe (10). For convenience, features that aresimilar or correspond to features of the first embodiment will again bereferenced with the same reference numerals.

In this embodiment, the system (100) includes a base station (310) and aplurality of wear sensors (110) spaced along a length of a pipe (10) andoperatively connected to the base station (310). Each wear sensor (110)is configured to detect wear in a wall (12) of the pipe (10).

The system (100) further includes a remotely accessible server (1000)operatively connected to the base station (310) for receiving andmonitoring data output from the sensors (110) via the base station(310). The server (1000) is configured to generate an alert in the formof an electronic notification to a computing device (700) of an operatoror the like when said data received from any one of the sensors (110) isindicative of irregular wear in the wall (12) of the pipe (10).

The wear sensors (110) in this embodiment are again spaced at regular 1m intervals along a length of the pipe (10) and are mounted to a lowerside or portion of the pipe (10).

Each wear sensor (110) is as previously described in respect of thefirst embodiment with the exception that the wear sensor (110) reportsits operational status to the base station (310) when polled.

Each wear sensor (110) again includes a communication module in the formof a cellular or radio modem for wirelessly connecting the sensor (110)to the remotely accessible server (1000) via the base station (310). Thebase station (310) and the sensors (110) may be operatively connectedvia a wireless network, which may include, among others, the Internet,LANs, WANs, GPRS network, a mobile communications network or a radionetwork (UHF-band).

Generally, the base station (310) functions as a bridge between theplurality of sensors (110) and the remotely accessible server (1000).

The base station (310) is located at or near the pipe (10).

The base station (310) includes a body (312) sized and shaped forhousing components and/or parts of the system (100), including at leastone power source and a communications module. The body (312) is formedfrom a durable material or materials configured to withstand externalenvironmental exposure, such as, e.g., plastic, concrete and/or metalmaterial or materials.

The base station (310) includes a communications module in the form of acellular or radio modem for wirelessly connecting to the sensors (110)and the remotely accessible server (1000).

The base station (310) further includes a power source in the form ofone or more rechargeable batteries for powering at least thecommunications module.

The base station (310) also includes a microcomputer, including one ormore processors and a memory, for receiving, monitoring and transmittingdata between the remotely accessible server (1000) and the sensors(110). The one or more processors may be low power processors.

The processors include multiple inputs and outputs coupled to thecommunications module for the receiving and transmitting of data. Inuse, the base station (310) periodically or continuously addresses eachsensor (110) and reports the operational status of the sensor (110) tothe server (1000). The operational status includes whether the sensor(110) is operational, i.e., intact, an indication of any faults reportedby the sensor (110), and/or an indication of the battery chargeremaining.

FIG. 4 shows a third embodiment of the system (100) for monitoring wearalong a length of a pipe (10). For convenience, features that aresimilar or correspond to features of the first and second embodimentswill again be referenced with the same reference numerals.

In this embodiment, the system (100) include a base station (310) and aplurality of sensor nodes (410) operatively connected to the basestation (310). Each sensor node (410) is operatively associated with aplurality of wear sensors (110) and configured to detect wear in a wall(12) of the pipe (10).

The system (100) further includes a remotely accessible server (1000)operatively connected to the base station (310) for receiving andmonitoring data output from the sensors (110) via the sensor nodes(410). The server (1000) is configured to generate an alert in the formof an electronic notification to a computing device (700) of an operatoror the like when said data received from any one of the sensors (110) isindicative of irregular wear in the wall (12) of the pipe (10).

The wear sensors (110) in this embodiment are again spaced at regular 1m intervals along a length of the pipe (10) and are mounted to a lowerside or portion of the pipe (10).

Each wear sensor (110) is as previously described in respect of thefirst and second embodiments with the exception that the wear sensor(110) reports its operational status to the sensor node (310) whenpolled.

The sensor nodes (410) relay data between the sensors (110) and theserver (1000), via the base station (310).

Like with the base station (310), each sensor node (410) includes a body(412) sized and shaped for housing components and/or parts of the system(100), including a power source and a communications module. The body(412) is formed from a durable material or materials configured towithstand external environmental exposure, such as, e.g., plastic,concrete and/or metal material or materials.

As shown, each sensor node (410) is operatively associated with fourwear sensors (110) via a wired connection. Accordingly, each sensor node(410) is located at or near the pipe (10) in the immediate vicinity ofthe wear sensors (110) to which it is connected.

As indicated above, each sensor node (410) includes communication modulefor communicating with both the sensors (110) and the sever (800) viathe base station (310). The communication module includes a port oraccess point for connecting the sensors (110) via a cable.

The communications module is in the form of a cellular or radio modemfor wirelessly connecting to the base station (310).

Each sensor node (410) further includes a power source in the form ofone or more rechargeable batteries for powering at least thecommunication module and polling the sensors (110).

Again and like with the base station (310), each sensor node (410)further includes a microcomputer, including one or more processors and amemory, for receiving, monitoring and transmitting data between the basestation (310) and the sensors (110). The one or more processors are lowpower processors.

Again, the processors include multiple inputs and outputs coupled to thecommunications module for the receiving and transmitting of data. Inuse, each sensor node (410) periodically or continuously address eachsensor (110) operatively associated with the node (410) and report theoperational status of the sensor (110) and the node (410) to theremotely accessible server (1000) via the base station (310). Theoperational status again includes whether the sensor (110) isoperational, i.e., intact, an indication of any faults reported by thesensor (110), and/or an indication of the battery charge remaining.

A method (900) of using the system (100) as shown in FIGS. 2 to 4 is nowdescribed in detail with reference to FIG. 9.

At step 910, the providing includes the forming of senor inlet ports(18; not shown) in the sidewall (12) of the pipe (10) at spacedintervals corresponding to the desired spaced intervals for the sensor(110). The threaded openings coinciding as the sensor inlet ports (18;not shown) can be thrilled into the sidewall (12) of the pipe (10).

Once the senor inlet ports (18; not shown) are formed in the sidewall(12) of the pipe (10), a sensors (110) can be threadingly received ineach senor inlet port (18; not shown).

At step 920, the receiving and monitoring of data output from thesensors (110) includes addressing each sensor (110) to verify that thesensor probe (112; not shown) is intact. The verifying includestransmitting an electrical current through the electrical circuit (116;not shown) provided on the sensor probe (112; not shown), wherein aclosed circuit is indicative that the sensor (110) is intact and whereinan interrupted or open circuit is indicative that the sensor (110) hasbeen partially destroyed and thus irregular wear has occurred on aportion of the pipe (10) at least adjacent the sensor (110).

At step 930, responsive to the remotely accessible server (1000)identifying data indicative of irregular wear, the server (1000)generates an alert in the form of an electronic notification advising ofthe irregular wear to a computing or mobile device of an operator or thelike.

The electronic notification can be effected by way of Short MessageServer (SMS) protocol, Unstructured Supplementary Service Data (USSD)protocol, over a secure Internet connection, or by way of datacommunication enabled by software installed on the computing device.

In the present specification and claims (if any), the word ‘comprising’and its derivatives including ‘comprises’ and ‘comprise’ include each ofthe stated integers but does not exclude the inclusion of one or morefurther integers.

Reference throughout this specification to ‘one embodiment’ or ‘anembodiment’ means that a particular feature, structure, orcharacteristic described in connection with the embodiment is includedin at least one embodiment of the present invention. Thus, theappearance of the phrases ‘in one embodiment’ or ‘in an embodiment’ invarious places throughout this specification are not necessarily allreferring to the same embodiment. Furthermore, the particular features,structures, or characteristics may be combined in any suitable manner inone or more combinations.

In compliance with the statute, the invention has been described inlanguage more or less specific to structural or methodical features. Itis to be understood that the invention is not limited to specificfeatures shown or described since the means herein described comprisespreferred forms of putting the invention into effect. The invention is,therefore, claimed in any of its forms or modifications within theproper scope of the appended claims (if any) appropriately interpretedby those skilled in the art.

1. A pipe wear monitoring system including: at least one base station; aplurality of wear sensors spaced along a length of a pipe andoperatively connected to the at least one base station, each wear sensorconfigured to detect wear in a wall of the pipe; and at least oneremotely accessible server operatively connected to the base station forreceiving and monitoring data output from said sensors via said at leastone base station, said server configured to generate an alert when saiddata received from any one of the plurality of wear sensors isindicative of irregular wear in the wall of the pipe.
 2. A pipe wearmonitoring system including: at least one base station; a plurality ofsensor nodes operatively connected to the at least one base station,each sensor node operatively associated with at least one wear sensorspaced along a length of a pipe and configured to detect wear in a wallof the pipe; and at least one remotely accessible server operativelyconnected to the base station for receiving and monitoring data outputfrom said sensors via said sensor nodes, said server configured togenerate an alert when said data received from any one of the pluralityof wear sensors is indicative of irregular wear in the wall of the pipe.3. The system of claim 1, wherein each of the plurality of wear sensorsor the at least one wear sensor is fitted or installed to a sidewall ofthe pipe to detect wear in an inner surface of the sidewall of the pipe.4. The system of claim 1, wherein the wear sensors are spaced at regularintervals along a length of the pipe.
 5. The system of claim 1, whereinthe wear sensors are each at least partially received in a sensor inletport defined in an outer surface of a sidewall of the pipe.
 6. Thesystem of claim 5, wherein the sensor inlet port includes an openingdefined in the outer surface of the sidewall of the pipe and extends atleast partially towards an inner surface of the sidewall of the pipe. 7.The system of claim 1, wherein the wear sensors are electric sensorsconfigured to generate an electronic signal when a sidewall of the pipethins to a predetermined thickness.
 8. The system of claim 1, whereinthe wear sensors are sacrificial wear sensors including a sacrificialprobe configured to be at least partially destroyed in response to wearin a sidewall of the pipe, partial destruction of the probe beingindicative of said wear being detected.
 9. The system of claim 8,wherein the probe is an electronic sacrificial probe configured togenerate an electronic signal or the absence of an electronic signal asa result of the probe being at least partially destroyed.
 10. The systemof claim 9, wherein the sacrificial probe includes a board having atleast one electrical circuit defined thereon, said board and said atleast one circuit configured to be at least partially destroyed inresponse to wear in a sidewall of the pipe.
 11. The system of claim 9,wherein the sacrificial probe includes a board having a plurality ofelectrical circuits defined thereon, each individual circuit of theplurality and the board configured to be sequentially at least partiallydestroyed in response to wear in a sidewall of the pipe, whereinsequential at least partially destruction of each said individualcircuit enables wear in the sidewall to be incrementally monitored and awear rate to be determined.
 12. The system of claim 9, wherein the atleast one electrical circuit or the plurality of circuits arecontinuously or periodically polled by the system and wherein when thecircuit or one of the plurality of circuits is intact, the circuitgenerates an electrical signal when polled indicative of an absence ofirregular wear on the sidewall.
 13. The system of claim 1, wherein theat least one base station includes a communications module forconnecting the plurality of sensor or sensor nodes and the at least oneremotely accessible server.
 14. The system of claim 13, wherein thecommunications module is a modem enabling the at least one base stationto connect to the at least one remotely accessible server via a wirelessnetwork.
 15. A wear sensor for use in detecting irregular wear in a wallof a pipe, said sensor including: a sacrificial probe configured to beat least partially inserted into an opening defined in an outer surfaceof a sidewall of a pipe and be at least partially destroyed in responseto irregular wear on an inner surface of the pipe, the destruction ofthe probe being indicative of irregular wear being detected.
 16. Thewear sensor of claim 15, wherein the sacrificial probe includes a boardand a plurality of electrical circuits defined on the board, eachindividual circuit of the plurality and the board configured to besequentially at least partially destroyed in response to wear in thesidewall of the pipe, and wherein the sequential at least partiallydestruction of circuits enables the wear in the sidewall of the pipe tobe incrementally monitored and/or a wear rate to be determined.
 17. Amethod of monitoring pipe wear including: providing a plurality of wearsensors at spaced intervals along a length of a pipe, each sensor beingconfigured to detect wear in a wall of the pipe; and receiving andmonitoring data corresponding to data output from said sensors andgenerating an alert when data is received from any one of the pluralityof wear sensors indicative of irregular wear in the wall of the pipe.18. The method of claim 17, wherein responsive to identifying dataindicative of irregular wear, the alert is generated and transmitted toa computing or mobile device of an operator or the like.
 19. The methodof claim 18, wherein the alert is an electronic notification and iseffected by way of SMS protocol, USSD protocol, over a secure internetconnection or by way of data communication enabled by a softwareapplication installed on the computing device.
 20. The method of claim17, wherein the receiving and monitoring data includes periodically orcontinually addressing each wear sensor and wherein the absence of aresponse is indicative of partially destruction of the sensor and thusirregular wear on a portion of the pipe.